BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to a raindrop sensor.
Description of the Related Art
[0002] Japanese Patent Issue No.
3701309 discloses an optical type raindrop sensor that detects raindrops attached to windshield
glass of a vehicle.
[0003] A raindrop sensor of this type includes a light-emitting element that emits light
to windshield glass, and a light-receiving element that receives light reflected by
the windshield glass, and detects raindrops based on a light receiving amount of the
light-receiving element.
[0004] The raindrop sensor of Japanese Patent Issue No.
3701309 has a prism (light guide member) fixed to a surface at a vehicle interior side, of
the windshield glass, and the prism guides the light emitted from the light-emitting
element to a raindrop detection region that is set in the windshield glass, and guides
the light reflected on the raindrop detection region to the light-receiving element.
[0005] The prism is pasted on and fixed to the windshield glass by an optically transparent
adhesive sheet that is interposed between the prism and the windshield glass. Accordingly,
when the prism is fixed to the windshield glass, air bubbles sometimes remain in a
contact interface between the adhesive sheet and the windshield glass.
[0006] Here, if air bubbles (layer of air) exist on a route of passage of light during a
time until the light emitted from the light-emitting element is received by the light-receiving
element, the light is reflected on the layer of air, and the light receiving amount
in the light-receiving element is reduced. Therefore, for a normal operation of the
raindrop sensor, it is necessary to prevent the layer of air from being interposed
on the route of the light.
[0007] Conventionally, air bubbles have been generally removed by bringing an adhesive sheet
into pressure contact with windshield glass, and moving the air bubbles that exist
in the contact interface to the outside of the contact interface by pressure.
[0008] However, the pressure contact force (urging force) necessary to remove air bubbles
is so large that when the raindrop sensor is mounted to windshield glass, the urging
force which brings the adhesive sheet into pressure contact therewith becomes a factor
that inhibits mounting of the raindrop sensor to the windshield glass.
[0009] Consequently, there is a growing demand that an air bubble is prevented from remaining
on the contact interface of an adhesive sheet and windshield glass while mounting
of a raindrop sensor to the windshield glass is facilitated.
SUMMARY OF THE INVENTION
[0010] The present invention is made in view of the aforementioned problems, and an object
of the present invention is to provide a raindrop sensor which can be easily mounted
to windshield glass and prevent air bubbles from remaining on a contact interface
of an adhesive sheet and a windshield glass. According to an aspect of the present
invention, a raindrop sensor in which a light guide member is mounted to a windshield
glass through an optically transparent elastic member, wherein the light guide member
guides light emitted from a light-emitting element to the windshield glass and guides
light reflected at the windshield glass to a light-receiving element, the raindrop
sensor comprising:
a bracket configured to be fixed to the windshield glass;
a cover configured to be attachable to and detachable from the bracket; and
a support member configured to support the light guide member in the cover to be capable
of advancing and retracting in a mounting direction to the windshield glass, wherein
the elastic member is configured by a gas-permeable silicon sheet containing silicon
oil,
when the cover is mounted to the bracket, the support member and the elastic member
are compressed in the mounting direction-and the light guide member is brought into
pressure contact with the windshield glass via the elastic member, and
a compression spring constant of the support member is set at a value smaller than
a compression spring constant of the elastic member, so that a compression amount
in the mounting direction of the elastic member at the time of mounting the cover
to the bracket becomes smaller than a compression amount in the mounting direction
of the support member.
[0011] The elastic member is the gas-permeable silicon sheet containing silicon oil, and
the silicon sheet has the property of eliminating air bubbles that exist between the
silicon sheet and the windshield glass, as a result that gas components are discharged
to outside through the inside of the silicon sheet after a time elapses with a very
small load (loading) acting on the silicon sheet, even if the air bubbles exist between
the silicon sheet and the windshield glass with which the elastic member is in contact.
[0012] Therefore, by only bringing the elastic member into pressure contact with the windshield
glass by applying a very small load, the air bubbles that exist between the elastic
member and the windshield glass can be removed. Accordingly, it is not necessary to
bring the elastic member into pressure contact with the windshield glass by applying
a large load, as in the conventional raindrop sensor, and therefore, mounting of the
raindrop sensor to the windshield glass is facilitated.
[0013] Further, the compression amount in the mounting direction of the elastic member at
the time of mounting the cover to the bracket is smaller than the compression amount
in the mounting direction of the support member, and therefore, even if the elastic
member is brought into pressure contact with the windshield glass with a very small
load, the influence of the error in the mounting direction of the elastic member to
the windshield glass is decreased. Accordingly, even if the elastic member is brought
into pressure contact with the windshield glass with a very small load, the optical
performance of the raindrop sensor can be favorably prevented from being reduced by
the influence of the error in the mounting direction.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects, features, and advantages of the present invention will become more
apparent from the following detailed description made with reference to the accompanying
drawings, in which like parts are designated by like reference numbers and in which:
Fig. 1 is an exploded perspective view of a raindrop sensor;
Figs. 2A and 2B are sectional views of the raindrop sensor;
Figs. 3A and 3B are sectional views of the raindrop sensor;
Fig. 4 is a plan view of the raindrop sensor seen from a windshield glass side;
Figs. 5A to 5D are views explaining mounting of a raindrop sensor main body to a bracket;
Figs. 6A and 6B are diagrams explaining compression of a spring and an optical contact;
Fig. 7 is a view explaining an error amount of the windshield glass; and
Figs. 8A to 8C are views explaining a relation of a variation in thickness of the
windshield glass, and a light irradiation region and a raindrop detection region.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] Hereinafter, an embodiment of the present invention will be described with a case
of a raindrop sensor 1 that detects raindrops attached to windshield glass 2 cited
as an example.
[0016] Fig. 1 is an exploded perspective view of the raindrop sensor 1. Figs. 2A and 2B
are sectional views of the raindrop sensor 1, wherein Fig. 2A is a sectional view
showing a portion of a case 7 cut at a surface A in Fig. 1 together with other constituent
elements of the raindrop sensor 1, and Fig. 2B is a sectional view taken along a line
A-A in Fig. 2A.
[0017] Figs. 3A and 3B are sectional views of the raindrop sensor 1, wherein Fig. 3A is
a sectional view taken along a line B-B in Fig. 2B, and Fig. 3B is a sectional view
taken along a line A-A in Fig. 3A. Fig. 4 is a plan view of the raindrop sensor 1
seen from a windshield glass 2-side, and is a view showing positions of springs Sp
by virtual lines. Note that in Fig. 2B and Figs. 3A and 3B, illustration of the windshield
glass 2 is omitted. Further, hereinafter, explanation will be made with an upper side
in Fig. 1 set as an upper part and a lower side in Fig. 1 set as a lower part for
the convenience of explanation.
[0018] The raindrop sensor 1 is configured by attaching a raindrop sensor main body 4 to
a bracket 3 fixed to the windshield glass 2.
[0019] The bracket 3 is formed by folding a metal sheet, and has a plate-shaped mounting
portion 30 that is fixed to the windshield glass 2.
[0020] In the embodiment, the mounting portion 30 is pasted on and fixed to an inner surface
2b at a vehicle interior side of the windshield glass 2 via an adhesive sheet Sh (see
Fig. 2A) that is pasted on a surface at a windshield glass 2-side, of the mounting
portion 30.
[0021] In a substantial center of the mounting portion 30, an opening 31 in a rectangular
shape is formed, and a detection region for raindrops (raindrop detection region)
that is set on the windshield glass 2 is exposed to an inner side of the opening 31.
[0022] At both sides of the opening 31, reinforcing wall portions 32 and 32 that are formed
by folding the mounting portion 30 to a side opposite to the windshield glass 2 are
provided, and rigidity strength at a perimeter of the opening 31 in the mounting portion
30 is enhanced by the reinforcing wall portions 32 and 32.
[0023] At one side in a longitudinal direction of the mounting portion 30, locking portions
33 and 33 to which latch portions 843 of a cover 8 that will be described later are
locked are formed by protruding downward from both side portions in a width direction
of the mounting portion 30.
[0024] The locking portions 33 and 33 are formed by folding both side portions of the mounting
portion 30 in the same direction as the reinforcing wall portion 32, and each has
a base portion 331 extending downward in a direction to be away from the mounting
portion 30, and an extending portion 332 that extends from a lower portion of the
base portion 331.
[0025] The extending portion 332 extends in a direction to be away from the opening 31 parallel
to the mounting portion 30, at a lower side from the reinforcing wall portion 32,
and the latch portion 843 of the cover 8 that will be described later is locked to
a side edge 332a, which is at a mounting portion 30-side, (upper side in the drawing)
of the extending portion 332.
[0026] At the other side in a longitudinal direction of the mounting portion 30, an engaging
portion 34 with which an engaging projection 821 (see Fig. 2A) of the cover 8 which
will be described later is engaged is provided to extend in the same direction as
the reinforcing wall portion 32. The engaging portion 34 is formed by folding a frame
portion 341 in a rectangular shape that is connected to the mounting portion 30 at
a base end side thereof, and has an elastic engaging portion 342 that extends upward
of a windshield glass 2-side at a side edge of a lower side of the frame portion 341.
[0027] The elastic engaging portion 342 is elastically deformable in the longitudinal direction
(lateral direction in Fig. 2 A) of the mounting portion 30, and when the raindrop
sensor main body 4 is mounted to the bracket 3, the engaging projection 821 of the
cover 8 which will be described later is snap-engaged with an engaging hole 342a (see
Fig. 4) of the elastic engaging portion 342.
[0028] As shown in Fig. 1, the raindrop sensor main body 4 includes an optical contact 5,
a prism 6, a case 7 (movable board), and the cover 8 in order from the windshield
glass 2-side.
[0029] In the raindrop sensor main body 4, the case 7 to which the prism 6 and a substrate
9 are attached is supported by the cover 8, and in the cover 8, the case 7 is supported
to be capable of advancing and retracting in a vertical direction in the drawing by
the springs Sp which are interposed between the case 7 and the cover 8.
[0030] The optical contact 5 forms a rectangular shape in a plan view, and is formed into
a size as is capable of being accommodated in the opening 31 which is provided in
the bracket 3.
[0031] The optical contact 5 is an elastic member having optical transparency, and in the
embodiment, a gas-permeable silicon sheet containing silicon oil is used therefor.
[0032] The optical contact 5 is pasted on a surface at a bracket 3-side, of the prism 6
(pasting portion 61) before the raindrop sensor main body 4 is mounted to the bracket
3, and when the raindrop sensor main body 4 is mounted to the bracket 3, the optical
contact 5 is held in a compressed state between the windshield glass 2 and the pasting
portion 61.
[0033] In this case, the gas permeable silicon sheet has a property of eliminating air
bubbles that exist between the silicon sheet, and the windshield glass 2 and the pasting
portion 61 as a result that gas components are discharged to outside through an inside
of the silicon sheet after a time elapses with a very small load (loading) acting
on the silicon sheet even if the air bubbles (gas components) exist between the silicon
sheet, and the windshield glass 2 and the pasting portion 61 with which the silicon
sheet is in contact.
[0034] The pasting portion 61 of the prism 6 is a plate-shaped portion on which the optical
contact 5 is pasted, and in a plan view, the pasting portion 61 is formed into a rectangular
shape of a size larger than the optical contact 5 to be capable of being accommodated
in the opening 31 of the bracket 3 (see Fig. 4).
[0035] At both side portions in a width direction of the pasting portion 61, engaging wall
portions 62 and 62 for engaging and supporting the prism 6 in the case 7 are formed
to extend to a case 7-side.
[0036] The engaging wall portions 62 and 62 respectively extend in a straight line along
side edges of the pasting portion 61, and engaging projections 62a are provided on
outer peripheral surfaces of the engaging wall portions 62 and 62 to protrude outward
in a radial direction (see Fig. 1 and Fig. 2B).
[0037] As shown in Fig. 2B, in the embodiment, the prism 6 is attached to the case 7 by
inserting the engaging wall portions 62 and 62 into an inner side of side wall portions
72 and 72 of the case 7, and on this occasion, the engaging projections 62a and 62a
on the prism 6 side are engaged with engaging holes 72a and 72a that are provided
in the side wall portions 72 and 72 on the case 7-side, whereby the prism 6 is inhibited
from falling off from the case 7.
[0038] In the prism 6, a light guide portion 63 is provided between the engaging wall portions
62 and 62, and as shown in Figs. 2A and 2B, the light guide portion 63 has light-emitting
side lens portions 64 and 64 on which light emitted from the light-emitting elements
91 and 91 is incident, and a light-receiving side lens portion 65 that guides light
reflected by the windshield glass 2 to a light-receiving element 92.
[0039] A lens diameter Da of each of the light-emitting side lens portions 64 and 64 is
set at a diameter larger than a lens diameter Db of the light-receiving side lens
portion 65, and a detection region DR for raindrops by the light-receiving element
92 is set to be narrower in contrast with an irradiation region IR of light in the
windshield glass 2.
[0040] This is for the purpose of preventing the detection region for raindrops from deviating
from the irradiation region of light by setting the detection region for raindrops
to be narrow because the irradiation region IR of the light from the light-emitting
element 91 displaces in the lateral direction in the figure in response to a thickness
Wa of the windshield glass 2 on which the raindrop sensor 1 is mounted.
[0041] Here, a relation of the irradiation region IR of light and the detection region DR
for raindrops will be described with reference to Figs. 8A to 8C. Figs. 8A to 8C are
views explaining a relation of a variation in thickness of the windshield glass 2,
and the irradiation region IR of light and the detection region DR for raindrops.
Fig. 8A shows a case in which the thickness of the windshield glass 2 is a thickness
Wb larger than the reference thickness Wa shown in Fig. 8B, Fig. 8B shows a case in
which the thickness of the windshield glass 2 is the reference thickness Wa, and Fig.
8C shows a case in which the thickness of the windshield glass 2 is a thickness Wc
smaller than the reference thickness Wa shown in Fig. 8B, respectively.
[0042] The light that is emitted from the light-emitting element 91 and is incident on the
inside of the light guide portion 63 from the light-emitting side lens portion 64
is refracted by the light-emitting side lens portion 64 to be parallel light in a
direction of approximately 45° with respect to the surface 2a of the windshield glass
2. A refraction index of the prism 6, a refraction index of the optical contact 5,
and a refraction index of the windshield glass 2 are substantially the same, and the
parallel light that is refracted by the light-emitting side lens portion 64 reaches
the surface 2a of the windshield glass 2 while keeping the angle, and forms the irradiation
region IR of the light with a predetermined width that is determined in accordance
with the lens diameter Da, on the surface 2a of the windshield glass 2.
[0043] In this case, the width of the irradiation region IR of light is approximately 1.4
times as large as the lens diameter Da.
[0044] The parallel light which reaches the surface 2a of the windshield glass 2 is totally
reflected on the surface 2a due to a difference between the refraction index (approximately
1.5) of the windshield glass 2 and the refraction index (approximately 1.0) of air,
and remains to be parallel light to return into the prism 6.
[0045] Subsequently, the parallel light is totally reflected on a wall portion at a right
side of the light guide portion 63, and reaches the light-receiving side lens portion
65. The parallel light that reaches the light-receiving side lens portion 65 is refracted
by the light-receiving side lens portion 65 and are collected and condensed by the
light-receiving element 92.
[0046] In this case, a range of the parallel light which is refracted at the light-receiving
side lens portion 65 (the detection region DR for raindrops by the light-receiving
element 92) is a predetermined width determined in accordance with a lens diameter
Db of the light-receiving side lens portion 65, and the predetermined width is approximately
1.4 times as large as the lens diameter Db.
[0047] In this case, if the thickness of the windshield glass 2 is the thickness Wb which
is larger than the reference thickness Wa, the irradiation region IR of light moves
in a direction to be away from the light-emitting element 91 (the right direction
in the figure) (see Fig. 8A), and when the thickness of the windshield glass 2 becomes
the thickness Wc which is smaller than the reference thickness Wa, the irradiation
region IR of light moves in a direction to be close to the light-emitting element
91 (left direction in the figure) (see Fig. 8C).
[0048] Therefore, in the embodiment, the lens diameter Da of the light-emitting side lens
portion 64 and the lens diameter Db of the light-receiving side lens portion 65 are
set so that when the thickness of the windshield glass 2 is the reference thickness
Wa, the detection region DR for raindrops is set substantially in the center of the
irradiation region of the irradiation region IR of light, and when the thickness of
the windshield glass 2 is within an error range of the reference thickness Wa (between
the thickness Wc and the thickness Wb), the detection region DR for raindrops can
be prevented from deviating from the irradiation region of the irradiation region
IR of light (see Fig. 8B).
[0049] For example, in the embodiment, the lens diameter Da and the lens diameter Db are
set to satisfy the following condition: the lens diameter Da of the light-emitting
side lens portion 64 - the lens diameter Db of the light-receiving side lens portion
65 ≥ 1.0 mm /1.4 (Da-Db≥1.0 mm/1.4), when the error of the thickness of the windshield
glass 2 is ±0.5 mm.
[0050] Thereby, the detection region DR for raindrops can be reliably positioned in the
irradiation region IR of light when the thickness of the windshield glass 2 is within
the predetermined error range. Accordingly, even if an error exits in the thickness
of the windshield glass 2, the detection region DR for raindrops becomes within the
irradiation region IR of light, and therefore, optical stability of the raindrop sensor
1 is improved.
[0051] It should be noted that it is also conceivable to make the lens diameter Db of the
light-receiving side lens portion 65 larger than the lens diameter Da of the light-emitting
side lens portion 64, in this case, however, noise light such as sunlight is easily
incident thereon, and therefore, optical performance is reduced.
[0052] As shown in Fig. 2A, an opening 71 a is formed in a base portion 71 of the case 7
to which the prism 6 is attached in order to ensure a route of light that travels
to the prism 6 from the light-emitting elements 91 and 91, and a route of light that
travels to the light-receiving element 92 from the prism 6, and the substrate 9 including
the light-emitting element 91 and the light-receiving element 92 is mounted on a surface
at a side opposite to the prism 6 in the base portion 71.
[0053] Therefore, in the raindrop sensor 1 according to the embodiment, the light emitted
from the light-emitting element 91 is incident on the inside of the light guide portion
63 from the light-emitting side lens portion 64 through the opening 71 a provided
in the base portion 71, and thereafter, passes through the light guide portion 63
and the optical contact 5 to be reflected by the surface 2a of the windshield glass
2. Subsequently, the light reflected by the windshield glass 2 passes through the
optical contact 5 and the light guide portion 63 again, and thereafter is received
by the light-receiving element 92 via the opening 71 a from the light-receiving side
lens portion 65.
[0054] As shown in Fig. 1 and Fig. 2A, the substrate 9 is mounted to an undersurface of
the case 7 by being locked by a locking claw 75 that extends downward at the side
opposite to the prism 6 from a side edge portion of the case 7, and one end 76a of
a connector terminal 76 that forms an L-letter shape in a side view is connected to
one side in a longitudinal direction of the substrate 9.
[0055] The connector terminal 76 extends in a direction orthogonal to the substrate 9 in
the base portion 71 of the case 7, and thereafter, extends parallel to the substrate
9 toward a connector portion 77 that is adjacent to the base portion 71, and the other
end 76b of the connector terminal 76 is located in a cylindrical wall 771 of the connector
portion 77 (see Fig. 2A and Fig. 3B).
[0056] Figs. 5A to 5D are views explaining assembly of the raindrop sensor main body 4 to
the bracket 3. Fig. 5A is a sectional view of the raindrop sensor main body 4 before
assembled to the bracket 3. Fig. 5B is a view showing a state in which the latch portion
843 at the raindrop sensor main body 4 side is locked to the locking portion 33 of
the bracket 3. Fig. 5C is a view showing a state directly before the engaging projection
821 at the raindrop sensor main body 4-side is snap-engaged with the elastic engaging
portion 342 of the bracket 3. Fig. 5D is a view showing a state in which the raindrop
sensor main body 4 is mounted to the bracket 3.
[0057] Figs. 6A and 6B are diagrams schematically explaining a compression state of the
spring Sp and the optical contact 5. Fig. 6A is a diagram schematically showing a
change of the compression state of the spring Sp. Fig. 6B is a diagram schematically
showing a change of the compression state of the optical contact 5.
[0058] Fig. 7 is a view explaining an error amount by the windshield glass 2.
[0059] As shown in Fig. 1, support shafts 73 for the springs Sp are provided at four corners
of the base portion 71 of the case 7. The support shaft 73 extends in a straight line
toward a lower part at the cover 8-side, and one end side of the spring Sp is mounted
to each of the support shafts 73 by being fitted over each of the support shafts 73.
[0060] The spring Sp has a free length L0 (see a free length in Fig. 6A), wherein in a state
in which one end side thereof is fitted on the support shaft 73, the other end side
protrudes downward of the cover 8-side.
[0061] In the embodiment, when the case 7 and the cover 8 are assembled by engaging an engaging
claw 72b provided at a side wall portion 72 of the case 7 with an engaging recessed
portion 82b provided in a peripheral wall portion 82 of the cover 8, a tip end side
of the support shaft 73 is inserted into a support stand 83 in a cylindrical shape
provided on a wall portion 81 of the cover 8 (see Fig. 5A).
[0062] In this state, the other end at the cover 8-side, of the spring Sp is pressed by
an upper end 83a (see Fig. 3A) of the support stand 83, and the spring Sp is compressed
in the axial direction until a length of the spring Sp becomes from the free length
L0 to a predetermined length L1 (see Fig. 5A and before bracket assembly in Fig. 6A).
[0063] In this state, the case 7 is supported by the cover 8 in a state movable in the
vertical direction, and disposes the pasting portion 61 of the prism 6 which is assembled
to the case 7 at a position protruding upward from an upper end 82a of the peripheral
wall portion 82 of the cover 8.
[0064] As shown in Fig. 4, the springs Sp are provided at positions symmetrical across a
center line Lm of the optical contact 5 in the longitudinal direction of the bracket
3 by being spaced in the width direction of the optical contact 5. The respective
springs Sp are located in corners of a virtual line Im in a quadrangular shape surrounding
the optical contact 5, so that urging forces from the respective springs Sp uniformly
act on the optical contact 5, and the optical contact 5 is brought into pressure contact
with the windshield glass 2 with uniform loads throughout the entire surface thereof.
[0065] As shown in Fig. 1, in the cover 8, a connector cover portion 84 is integrally formed
in the peripheral wall portion 82 that surrounds an outer periphery of the case 7.
The connector cover portion 84 extends sideway of the peripheral wall portion 82 along
an extending direction of the connector portion 77, and has a wall portion 841 that
covers an undersurface of the cylindrical wall 771 of the connector portion 77, and
side wall portions 842 and 842 that cover both sides of the cylindrical wall 771.
[0066] The wall portion 841 of the connector cover portion 84 is located at an upper part
at a windshield glass 2-side from the wall portion 81 of the cover 8, and the side
wall portion 842 of the connector cover portion 84 is located inward from the peripheral
wall portion 82 of the cover 8, seen from the protruding direction side of the connector
cover portion 84.
[0067] At tip end portions of the side wall portions 842 and 842, the latch portions 843
that are latched and locked to the mounting portion 30 of the bracket 3 described
above are provided. The latch portions 843 and 843 are provided to protrude sideward
from the side wall portions 842, and each has a predetermined thickness Wx in a height
direction of the side wall portion 842, as shown in Fig. 3A.
[0068] A lower side 843a of the latch portion 843 extends in a straight line to the peripheral
wall portion 82-side from a tip end of the side wall portion 842, and a peripheral
wall portion 82 side (left side in the figure) of the lower side 843a becomes an inclined
surface 843b in a direction in which thicknesses of the latch portions 843 and 843
become thinner toward the peripheral wall portion 82.
[0069] As shown in Fig. 1 and Fig. 4, at a base end side of the side wall portion 842, outer
wall portions 844 and 844 parallel to the side wall portion 842 are provided. The
outer wall portions 844 and 844 extend in a straight line along the side wall portion
842, in positions separated sideway from the side wall portions 842 and 842.
[0070] In the embodiment, when the latch portion 843 is latched and locked to the mounting
portion 30 of the bracket 3, the locking portion 33 (base portion 331) of the mounting
portion 30 is inserted between the outer wall portion 844 and the side wall portion
842, and positioning of the cover 8 in the width direction of the bracket 3 is performed.
[0071] Therefore, at tip end portions of the outer wall portions 844 and 844, reinforcement
walls 844a and 844a that extend in directions to separate from the side wall portions
842 and 842 are provided, and rigidity strength of the outer wall portions 844 and
844 is enhanced by the reinforcement walls 844a and 844a.
[0072] Hereinafter, assembly of the raindrop sensor main body 4 to the bracket 3 will be
described.
[0073] When the case 7 in which the prism 6 and the substrate 9 are assembled is assembled
to the cover 8 to construct the raindrop sensor main body 4 first, the springs Sp
which support the case 7 are compressed in the axial direction until the length thereof
becomes the predetermined length L1 from the free length L0 (see Fig. 5A and Fig.
6A).
[0074] In this state, the case 7 is supported by the cover 8 in the state movable in the
vertical direction in Fig. 5A, and disposes the pasting portion 61 of the prism 6
which is assembled to the case 7 in the position protruding upward from the upper
end 82a of the peripheral wall portion 82 of the cover 8.
[0075] As shown in Fig. 5B, the bracket 3 is pasted on and fixed to the inner surface 2b
at the vehicle interior side, of the windshield glass 2, via the adhesive sheet Sh,
and when the raindrop sensor main body 4 is mounted to the bracket 3, the latch portions
843 provided at the cover 8 of the raindrop sensor main body 4 are locked to the locking
portions 33 of the bracket 3 first.
[0076] On this occasion, the raindrop sensor main body 4 is locked to the locking portions
33 in an orientation in which the inclined surfaces 843b of the latch portions 843
are along the top surfaces 332a of the extending portions 332 of the locking portions
33.
[0077] Subsequently, the raindrop sensor main body 4 is rotated with the vicinity of an
intersection P between the base portion 331 and the extending portion 332 in the locking
portion 33 as a fulcrum, and the optical contact 5 is rotated to a direction to access
to the opening 31 of the bracket 3 (see the arrow in the figure).
[0078] Thereupon, the engaging portion 34 (frame portion 341) provided at the bracket 3
is inserted into the gap between the cover 8 and the case 7, and the engaging projection
821 provided at the peripheral wall portion 82 of the cover 8 engages with the elastic
engaging portion 342 while elastically deforming the elastic engaging portion 342
of the engaging portion 34, whereby mounting of the raindrop sensor main body 4 to
the bracket 3 is completed (see Figs. 5C and D).
[0079] On this occasion, the optical contact 5 is compressed between the inner surface 2b
of the windshield glass 2 and the pasting portion 61 of the prism 6, and is compressed
to a thickness W2 that is smaller than a thickness W1 before compression. Further,
the spring Sp which supports the case 7 with the cover 8 is also compressed between
the case 7 and the cover 8, and is compressed from a length L1 at the time of supporting
the case 7 with the cover 8 to a length L2 that is shorter than the length L1 (see
Fig. 5D).
[0080] It should be noted that the optical contact 5 is brought into pressure contact with
the windshield glass 2 from the fulcrum side (the right side in the figure) of rotation
of the raindrop sensor main body 4. As a result, the optical contact 5 is in pressure
contact with the windshield glass 2 while pushing out the air bubbles existing between
the optical contact 5 and the windshield glass 2 to the engaging projection 821-side
(the left side in the figure), and therefore, when mounting of the raindrop sensor
main body 4 to the bracket 3 is completed, the air bubbles existing between the optical
contact 5 and the windshield glass 2 can be decreased.
[0081] In the embodiment, a compression spring constant k1 of the spring Sp is set at a
value smaller than a compression spring constant k2 of the optical contact 5, and
thereby a compression amount (ΔW=W1-W2) of the optical contact 5 becomes smaller than
a compression amount of the spring Sp (ΔLb=L1-L2) when the raindrop sensor main body
4 is mounted to the bracket 3 while the optical contact 5 is brought into pressure
contact with the inner surface 2b of the windshield glass 2 (ΔLb<ΔW).
[0082] The compression amount (ΔLb=L1-L2) of the spring Sp at this time is set to be smaller
than a compression amount (ΔLa=L0-L1) of the spring Sp at the time of supporting the
case 7 with the cover 8 (ΔLb<ΔLa).
[0083] Here, loads that act on the spring Sp and the optical contact 5 will be described.
[0084] When a change amount of the compression amount of the spring Sp due to a variation
amount ΔF of a load is set as ΔLb, a change amount of the compression amount of the
optical contact 5 due to the variation amount ΔF of a load is set as ΔW, and the change
amount of the total compression amount due to the variation amount ΔF of a load is
set as ΔX, with the compression spring constant of the spring Sp set as k1 and the
compression spring constant of the optical contact 5 set as k2, ΔLb=ΔF/k1, ΔW=ΔF/k2,
and ΔX=ΔLb+ΔW are satisfied.
[0085] Here, when ΔF=1, k1=1 and k2=10, for example, ΔLb=1, ΔW=0.1 and ΔX=1.1 are made,
a influence degrees of the change amount ΔLb of the compression amount of the spring
Sp and the change amount ΔW of the compression amount of the optical contact 5, to
the change amount ΔX of the total compression amount are such that the influence degree
of the spring Sp ΔLb/ΔX=90%, and the influence degree of the optical contact 5 ΔW/ΔX=10%.
[0086] Accordingly, if the compression spring constant k1 of the spring Sp is set at a value
sufficiently smaller than the compression spring constant k2 of the optical contact
5, the influence of the variation in the compression amount of the optical contact
5 becomes small with respect to a displacement error such as a bonding error of the
bracket 3 in the parallel direction with the windshield glass 2, and optical performance
in the raindrop sensor 1 is stabilized.
[0087] In the raindrop sensor according to the embodiment, the compression spring constant
k2 of the optical contact 5 is set to be 1/5 of the compression spring constant k1
of the spring Sp or less, more preferably 1/10 of the compression spring constant
k1 or less, so that the influence degree of the optical contact 5 becomes 20% or less.
[0088] Further, in the embodiment, a minimum compression amount (stroke amount) of the spring
Sp at the time of mounting the raindrop sensor main body 4 to the bracket 3 is set
so that when the raindrop sensor main body 4 is mounted to the bracket 3, the compression
amount (ΔLb=L1-L2) of the spring Sp becomes larger than a value obtained by adding
up an error amount (error amount Ld) in the mounting direction of the raindrop sensor
main body 4, which is determined in accordance with a curvature of the windshield
glass 2, and an error amount Lg in the mounting direction of the adhesive sheet Sh
which is used in fixation of the bracket 3 to the windshield glass 2, as shown in
Fig. 7.
[0089] As shown in Fig. 7, in the windshield glass 2 for a vehicle, the inner surface 2b
on which the raindrop sensor 1 is mounted forms a concave curved surface. Here, when
a radius of the curved surface of the windshield glass 2 is R 2500 mm, and a width
W of a contact surface of the optical contact 5 is 30 mm, the error amount becomes
Ld=0.05 mm (50 µm).
[0090] Consequently, the stroke amount of the spring Sp necessary to bring the optical contact
5 into close contact with the windshield glass 2 along the curved surface of the windshield
glass 2 is 0.05 mm (50 µm).
[0091] When a variation Lg (a variation in the direction to bring the optical contact 5
into pressure contact with the windshield glass 2) in a bonding height by the adhesive
sheet Sh between the windshield glass 2 and the bracket 3 is ±0.25 mm, the required
stroke amount of the spring is 0.50+0.05=0.55 (approximately 0.6 mm).
[0092] Accordingly, the optical contact 5 can be reliably brought into pressure contact
with the windshield glass 2 by making the minimum compression amount of the spring
Sp at the time of mounting the raindrop sensor main body 4 to the bracket 3 (stroke
amount: change amount ΔLb_min) larger than a stroke amount calculated from the radius
of the curved surface of the windshield glass 2, the error amount Ld determined in
accordance with the width W of the contact surface of the optical contact 5, and the
variation Lg in the bonding height by the adhesive sheet Sh, and therefore, the optical
performance in the raindrop sensor 1 is stabilized.
[0093] Further, in the raindrop sensor 1 of the embodiment, the compression amount (ΔLb=L1-L2)
of the spring Sp at the time of mounting the raindrop sensor main body 4 to the bracket
3 is set to be sufficiently smaller than the compression amount (ΔLa=L0-L1) of the
spring Sp at the time of supporting the case 7 by assembling the case 7 to the cover
8.
[0094] In the raindrop sensor according to the embodiment, the compression amount ΔLb of
the spring Sp at the time of mounting the raindrop sensor main body 4 to the bracket
3 is set to be 1/5 of the compression amount ΔLa of the spring Sp at the time of supporting
the case 7 by assembling the case 7 to the cover 8 or less, preferably 1/10 of the
compression amount ΔLa, or less.
[0095] Here, the influence of the error in the mounting height of the bracket 3, and the
minimum load that acts on the optical contact 5 will be described with the compression
spring constant k1 of the spring Sp set as 0.5 kg/mm, the compression spring constant
k of the optical contact 5 set as 2.5 kg/mm, the compression amount ΔLa of the spring
Sp at the time of supporting the case 7 by assembling the case 7 to the cover 8 set
as 5 mm, and the compression amount ΔLb of the spring Sp at the time of mounting the
raindrop sensor main body 4 to the bracket 3 set as 1 mm.
[0096] Before the raindrop sensor main body 4 is mounted to the bracket 3, a load F0 that
acts on the spring Sp is F0=k1 x5 mm=2.5 kg.
[0097] After the raindrop sensor main body 4 is mounted to the bracket 3, a load F1 that
acts on the spring Sp is F1=k1×(5+1) mm=3 kg.
[0098] A load error ΔF (error of a load that acts on the optical contact) due to an error
of the mounting height of the bracket 3 and the like at the time of mounting the raindrop
sensor main body 4 to the bracket 3 is 0.5 kg (=3 kg-2.5 kg).
[0099] Here, an error Δx of the compression amount of the optical contact 5 to the load
error (0.5 kg) is Δx=ΔF/k2=0.5/5=0.1 mm.
[0100] Accordingly, in this case, the influence of the error 1 mm of the mounting height
of the bracket 3 is reduced to 0.1 mm, and the minimum load that acts on the optical
contact is 2.5 kg.
[Comparative example 1]
[0101] An influence of an error of a mounting height of the bracket 3 and a minimum load
that acts on the optical contact 5, in the case of a comparative example in which
the free length L0 of the spring Sp is made short, and the compression amount (ΔLa=L0-L1)
of the spring Sp at the time of supporting the case 7 by assembling the case 7 to
the cover 8 and the compression amount (ΔLb=L1-L2) of the spring Sp at the time of
mounting the raindrop sensor main body 4 to the bracket 3 are made the same will be
described.
[0102] When the compression spring constant k1 of the spring Sp is set at 0.5 kg/mm, the
compression spring constant k of the optical contact 5 is set at 2.5 kg/mm, the compression
amount Δa of the spring Sp at the time of supporting the case 7 by assembling the
case 7 to the cover 8 is set at 1 mm, and the compression amount ΔLb of the spring
Sp at the time of mounting the raindrop sensor main body 4 to the bracket 3 is set
at 1 mm,
the load F0 that acts on the spring Sp before the raindrop sensor main body 4 is mounted
to the bracket 3 is F0=k1 x1 mm=0.5 kg.
[0103] After the raindrop sensor main body 4 is mounted to the bracket 3, the load F1 that
acts on the spring Sp is F1 =k1 x(1 +1) mm=1 kg.
[0104] The load error ΔF by an error of the mounting height of the bracket 3 and the like
at the time of mounting the raindrop sensor main body 4 to the bracket 3 is 0.5 kg
(=1 kg-0.5 kg).
[0105] The error Δx of the compression amount of the optical contact 5 to the load error
(0.5 kg) is Δx=ΔF/k2=0.5/5=0.1 mm.
[0106] Accordingly, when the compression amount (ΔLa=L0-L1) of the spring Sp at the time
of supporting the case 7 by assembling the case 7 to the cover 8, and the compression
amount (ΔLb=L1-L2) of the spring Sp at the time of mounting the raindrop sensor main
body 4 to the bracket 3 are made the same, the minimum load that acts on the optical
contact 5 reduces to 0.5 kg, although the influence of the error of 1 mm of the mounting
height of the bracket 3 is reduced to 0.1 mm.
[Comparative example 2]
[0107] An influence of an error of a mounting height of the bracket 3, and a minimum load
that acts on the optical contact 5 will be described in a case of a comparative example
in which the spring constant of the spring Sp is made large, and a difference between
the compression spring constant of the spring and the compression spring constant
of the optical contact 5 is reduced.
[0108] When the compression spring constant k1 of the spring Sp is set at 2.5 kg/mm, the
compression spring constant k2 of the optical contact 5 is set at 5 kg/mm, the compression
amount ΔLa of the spring Sp at the time of supporting the case 7 by assembling the
case 7 to the cover 8 is set at 1 mm, and the compression amount ΔLb of the spring
Sp at the time of mounting the raindrop sensor main body 4 to the bracket 3 is set
at 1 mm,
the load F0 that acts on the spring Sp, before mounting the raindrop sensor main body
4 to the bracket 3 is F0=k1 x1 mm=2.5 kg.
[0109] The load F1 that acts on the spring Sp after mounting the raindrop sensor main body
4 to the bracket 3 is F1=k1×(1+1) mm=5 kg.
[0110] The load error ΔF due to an error of the mounting height of the bracket 3 and the
like at the time of mounting the raindrop sensor main body 4 to the bracket 3 is 2.5
kg (=5 kg-2.5 kg).
[0111] The error Δx of the compression amount of the optical contact 5 with respect to the
load error (2.5 kg) is Δx=ΔF/k2=2.5/5=0.5 mm.
[0112] Accordingly, when the difference between the compression spring constant of the spring
and the compression spring constant of the optical contact 5 is made small, the influence
of the error of 1 mm of the mounting height of the bracket 3 is 0.5 mm, and the influence
of the error becomes larger than in the case of the embodiment described above.
[0113] As above, as in the raindrop sensor 1 according to the embodiment, the compression
amount (ΔLb=L1-L2) of the spring Sp at the time of mounting the raindrop sensor main
body 4 to the bracket 3 is set to be sufficiently smaller than the compression amount
(ΔLa=L0-L1) of the spring Sp at the time of supporting the case 7 by assembling the
case 7 to the cover 8, and the compression spring constant k1 of the spring Sp is
made sufficiently smaller than the compression spring constant k2 of the optical contact
5, whereby the influence of the error of the mounting height of the bracket 3 can
be restricted while the minimum load that acts on the optical contact 5 is ensured,
and therefore, the raindrop sensor 1 which is stable in the optical performance can
be provided.
[0114] As above, in the embodiment, a raindrop sensor 1 in which a prism 6 (light guide
member) that guides the light emitted from the light-emitting element 91 to the windshield
glass 2 and guides the light reflected at the surface 2a of the windshield glass 2
to the light-receiving element 92 is mounted to the windshield glass 2 via the optically
transparent optical contact 5 (elastic member), includes
the bracket 3 configured to be fixed to the windshield glass 2,
the cover 8 configured to be attachable to and detachable from the bracket 3, and
the spring Sp (support member) configured to support the prism 6 in the cover 8 to
be capable of advancing and retracting in the mounting direction to the windshield
glass 2,
the optical contact 5 is configured by a gas-permeable silicon sheet containing silicon
oil,
when the cover 8 is mounted to the bracket 3, the spring Sp and the optical contact
5 are compressed in the mounting direction, and the prism 6 is brought into pressure
contact with the windshield glass 2 via the optical contact 5, and
a compression spring constant k1 of the spring Sp is set at a value smaller than a
compression spring constant k2 of the optical contact 5, and a compression amount
ΔW (see Fig. 6) in the mounting direction of the optical contact 5 at the time of
mounting the cover 8 to the bracket 3 is made smaller than a compression amount ΔLb
(see Fig. 6) in the mounting direction of the spring Sp.
[0115] The optical contact 5 is a gas-permeable silicon sheet containing silicon oil, and
the gas-permeable silicon sheet has the property of eliminating air bubbles existing
between the silicon sheet, and the windshield glass 2 and the pasting portion 61,
as a result that gas components are discharged to outside through the inside of the
silicon sheet after a time elapses with a very small load (loading) acting on the
silicon sheet, even if the air bubbles (gas components) exist between the silicon
sheet, and the windshield glass 2 and the pasting portion 61 with which the silicon
sheet is in contact.
[0116] Therefore, by only bringing the optical contact 5 into pressure contact with the
windshield glass 2 by applying a very small load, the air bubbles existing between
the optical contact 5 and the windshield glass 2 can be removed. Accordingly, since
it is not necessary to bring the optical contact 5 into pressure contact with the
windshield glass 2 by applying a large load, as in the conventional raindrop sensor,
the load that is required when the raindrop sensor 1 is mounted to the windshield
glass 2 can be reduced, and therefore, a mounting operation of the raindrop sensor
1 can be facilitated.
[0117] Further, the compression amount ΔW in the mounting direction of the optical contact
5 at the time of mounting the cover 8 to the bracket 3 becomes smaller than the compression
amount ΔLb in the mounting direction of the spring Sp, and therefore, even if the
optical contact 5 is brought into pressure contact with the windshield glass 2 by
applying a very small load, the influence of the error in the mounting direction of
the optical contact 5 to the windshield glass 2 can be decreased.
[0118] Accordingly, even if the optical contact 5 is brought into pressure contact with
the windshield glass 2 by applying a very small load, the optical performance of the
raindrop sensor 1 can be favorably prevented from being reduced by the influence of
the error in the mounting direction.
[0119] The compression amount ΔLb of the spring Sp at the time of mounting the cover 8 to
the bracket 3 is set to be larger than a value obtained by adding up an error amount
Ld (error amount) in the mounting direction that is determined in accordance with
a curvature of the windshield glass 2, and an error amount Lg (error in the bonding
height) in the mounting direction of the bracket 3 that is fixed to the windshield
glass 2.
[0120] By the above configuration, the optical contact 5 can be brought into pressure contact
with the windshield glass 2 without receiving the influence of the error amount of
the windshield glass 2, and the error in the bonding height of the bracket, and therefore,
the optical performance of the raindrop sensor 1 can be favorably prevented from reducing
by receiving the influence of the error in the mounting direction.
[0121] Before the cover 8 is mounted to the bracket 3, the spring Sp supports the prism
6 to be capable of advancing and retracting in the mounting direction in a state in
which the spring Sp is compressed from a free length L0 (see Fig. 6A) of the spring
SP to a length L1, and
the compression amount of the spring Sp (ΔLb=L1-L2) at the time of mounting the cover
8 to the bracket 3 is set to be smaller than a compression amount of the spring Sp
(ΔLa=L0-L1) before mounting of the cover 8 to the bracket 3.
[0122] By the configuration as above, the load which is required at the time of mounting
the cover 8 to the bracket 3 can be restricted, and therefore, mounting of the raindrop
sensor 1 to the windshield glass 2 can be facilitated.
[0123] The prism 6 is provided to advance and retract in the mounting direction integrally
with a case 7 by being assembled to the case 7 that is supported to be capable of
advancing and retracting in the mounting direction in the cover 8, and
the spring Sp is configured to support the case 7 to be capable of advancing and retracting
in the mounting direction, and support two pairs of spots that are spaced in a width
direction of the prism 6 and are positions that are symmetrical around the center
of the optical contact 5, which is pasted on the surface (pasting portion 61), at
the windshield glass 2-side, of the prism 6, seen from the mounting direction.
[0124] By the configuration as above, urging forces act uniformly onto the optical contact
5 from the springs Sp which are provided at the four spots in total, and the optical
contact 5 is brought into pressure contact with the windshield glass 2 with a uniform
load throughout an entire surface thereof. Therefore, the optical performance of the
raindrop sensor 1 is stabilized.
[0125] The cover 8 is configured such that after the latch portion 843 provided at one end
side in the longitudinal direction of the cover is locked to the locking portion 33
provided at the bracket 3, the other end side in the longitudinal direction is rotated
in the circumferential direction around the engaging point P of the latch portion
843 and the locking portion 33, and while the optical contact 5 is compressed in the
mounting direction from the one end side (latch portion 843-side), the cover 8 is
mounted to the bracket 3.
[0126] By the configuration as above, while the air bubbles existing in the contact interface
between the optical contact 5 and the windshield glass 2 are pushed away to the other
end side, the optical contact 5 can be brought into pressure contact with the windshield
glass 2, and therefore, the content of the air bubbles in the contact interface directly
after the cover 8 is mounted to the bracket 3 and the optical contact 5 is brought
into pressure contact with the windshield glass 2 can be decreased.
[0127] The prism 6 includes the light-emitting side lens portion 64 on which the light emitted
by the light-emitting element 91 is incident, and the light-receiving side lens portion
65 that causes the light reflected at the windshield glass 2 to exit to the light-receiving
element 92, and the lens diameter Da of the light-emitting side lens portion 64 is
set to be a diameter larger than the lens diameter Db of the light-receiving side
lens portion 65.
[0128] By the configuration as above, the detection region DR for the raindrops by the light-receiving
element 92 becomes narrower in contrast with the irradiation region IR of light in
the windshield glass 2, and therefore, even if the irradiation region IR of the light
displaces in response to the thickness Wa of the windshield glass 2 to which the raindrop
sensor 1 is mounted, the detection region for raindrops can be prevented from deviating
from the irradiation region of light.
While only the selected embodiment has been chosen to illustrate the present invention,
it will be apparent to those skilled in the art from this disclosure that various
changes and modifications can be made therein without departing from the scope of
the invention as defined in the appended claims. Furthermore, the foregoing description
of the embodiment according to the present invention is provided for illustration
only, and not for the purpose of limiting the invention as defined by the appended
claims and their equivalents.
Description of Reference Signs
[0129]
- 1
- Raindrop sensor
- 2
- Windshield glass
- 2a
- Surface
- 2b
- Inner surface
- 3
- Bracket
- 4
- Raindrop sensor main body
- 5
- Optical contact
- 6
- Prism
- 7
- Case
- 8
- Cover
- 9
- Substrate
- 30
- Mounting portion
- 31
- Opening
- 32
- Reinforcing wall portion
- 33
- Locking portion
- 34
- Engaging portion
- 61
- Pasting portion
- 62
- Engaging wall portion
- 62a
- Engaging projection
- 63
- Light guide portion
- 64
- Light-emitting side lens portion
- 65
- Light-receiving side lens portion
- 71
- Base portion
- 71a
- Opening
- 72
- Side wall portion
- 72a
- Engaging hole
- 72b
- Engaging claw
- 73
- Support shaft
- 75
- Locking claw
- 76
- Connector terminal
- 76a
- One end
- 76b
- The other end
- 77
- Connector portion
- 81
- Wall portion
- 82
- Peripheral wall portion
- 82a
- Upper end
- 82b
- Engaging recessed portion
- 83
- Support stand
- 83a
- Upper end
- 84
- Connector cover portion
- 91
- Light-emitting element
- 92
- Light-receiving element
- 322a
- Top surface
- 331
- Base portion
- 332
- Extending portion
- 332a
- Side edge
- 341
- Frame portion
- 342
- Elastic engaging portion
- 342a
- Engaging hole
- 771
- Cylindrical wall
- 821
- Engaging projection
- 841
- Wall portion
- 842
- Side wall portion
- 842a
- Reinforcing wall
- 843
- Latch portion
- 843a
- Lower side
- 843b
- Inclined surface
- 844
- Outer wall portion
- A
- Surface
- Da
- Lens diameter
- Db
- Lens diameter
- DR
- Detection region
- F0
- Load
- F1
- Load
- IR
- Irradiation region
- Im
- virtual line
- L0
- Free length
- Lm
- Center line
- P
- Intersection
- P
- engaging point
- Sh
- Adhesive sheet
- Sp
- Spring
- W
- Width
- k
- Constant, k1 Constant, k2 Constant